5 Introduction: The control box is installed on the front left of the machine. This document covers hooking up the motors, proximity switches, spindle, VFD, emergency stop, and the three button pendant. Installation: Please refer to PRS Assembly Guide for control box installation. This document can be found at Powering the PRSstandard Control Box The power to the PRSstandard control box should be wired into a fused disconnect by a licensed electrician familiar with industrial equipment. The power requirements for the PRSstandard control box and router/spindle vary according to configuration. A schematic for the power requirements for the specific configuration is inside the door of the PRSstandard control box. Note: Since the power requirements for a Porter Cable router and for a spindle are different, different components are installed in the PRSstandard control box depending on which was requested. This is NOT user configurable; configurations were specified at the time these components were ordered. If different power requirements are necessary, please contact customer support. Exploring the PRSstandard Control Box Disconnect electrical power to the PRSstandard control box prior to this step! After the electrician has hooked up the PRSstandard control box and router or spindle, open the side of the box with a screwdriver (quarter turn). For safety reasons the door is designed lock open or closed unless the main power disconnect is turned off. Note: The PRSstandard control box has an interlock for the router/spindle. This interlock allows the power to the router/spindle to be disconnected, while not interrupting power to the machine. This adds additional safety for manual tool changes during a cutting file. Depending on the model, the control box may not look exactly the same as illustrated. Copyright 2016 ShopBot Tools, Inc. page 5

6 Inside the PRSstandard Control Box Note: Not all control boxes will be the same as pictured depending on specifications. The contactors, located at the top of PRSstandard control box, are the large relays that control power to the cutting head. They are controlled by software and relays on the control board for a router, and the E-Stop (main power disconnect) for a spindle. The size of the contactor may vary with the power requirements of the device it is powering. 1. Router/Spindle Interlock 2. Grounding Strip 3. Main Power Disconnect 4. Fuses 5. Contactors 6. Control Board 7. USB Cable 8. Roxtec Fixture 9. Motor Cables 10. Output Switches 11. Input Switches 12. Motor Drivers 13. Toroidal Transformer The Fuses in the PRSstandard control box (US 60Hz power) are dependent upon the setup: Porter Cable router (single): 1 5A fuse, 1 15A fuse Spindle: 1 5A fuse, no other fuses (spindles are protected by fused disconnect before the PRSstandard Control Box.) Copyright 2016 ShopBot Tools, Inc. page 6

7 Troubleshooting: Although the fused disconnect should protect the PRSstandard control box, if power is lost to everything in the PRSstandard control box, check the fuses and replace them with identical parts if necessary. Using the Roxtec Fixture Remove the Roxtec Fixture and pull cables through the side side of the control box. Ensure there is at least 10 of play available for the cables. The Roxtec Fixture gives all wires a tight entry and will seal the control box against dust and debris. Below is the manufacturer s suggested installation procedure. Lubricate the inside surfaces of the frame with Roxtec Assembly Gel especially in the corners. Insert the cables through the frame. Adapt the modules, which are to hold cables. Peel off layers until you achieve the gap seen in picture 4. Achieve a to 0.04 ( mm) gap between the two module halves when held against the cable. Copyright 2016 ShopBot Tools, Inc. page 7

8 Lubricate all modules thoroughly, both on the inside and the outside surfaces, before installation. Insert the modules from the back of the frame opening. If possible, start with the largest modules. To add more wires, loosen the fixture and remove as many layers as required to accommodate the wires. Then feed wire through and reinstall. Tighten the compression unit firmly to seal the frame. Maximum 7.83 ft. lb (10 Nm). A good indication is when the assembly gel is squeezed out between the modules. Notes: For optimum reliability, wait 24 hours or longer after installation before exposing the cables to strain or pressure. Try to route cables perpendicularly through the frame. Copyright 2016 ShopBot Tools, Inc. page 8

9 Once all of the cables have been attached inside the control box, run the cables through the modules and tighten the fixture to keep dust out of the control box. It may be necessary to run more than one of the smaller cables in the same gasket. Do not tigten the Roxtec modules completely (step 7) until all cables and wires are routed inside and out of the control box. Connecting VFD and Spindle Connecting the VFD logic cable into control box The logic cable is pre-wired into the VFD from the factory. It is the one coming out of the VFD without a connector. Inside it will be two wires, brown and white. This cable needs to be installed into the control box. Be sure the VFD is powered off before proceeding! Run the logic cable from the VFD through the Roxtec fixture on the right side of the control box. Use any available cable spaces or double up with an existing small wire. Connect the brown wire and the white wire from the logic cable into the VFD terminals on the Control Board labeled SPINDLE 1 (For a second spindle, you would use the terminals labeled SPINDLE 2 ). For Spindle #1, connect the brown wire to the F1 terminal and the white wire to the C1 terminal. For a second spindle, use the terminal connections F2 and C2. Attaching fan connection plug to HSD spindle Be sure the VFD is powered off before proceeding! Attach the fan connection plug to the front face of the HSD spindle. Tighten the screw inside the fan connection plug. Copyright 2016 ShopBot Tools, Inc. page 9

10 Attaching fan cable to 24v power supply The PRSstandard comes with a 24v power supply already installed in the control box. Strip back ~ ¼ of insulation from both the red and black wires at the loose end of the cable from the fan connection plug. Route the cable into the control box. Connect the red wire to the right side of the fuse marked 24 V (circled at left). Connect the black wire to any empty ground (G) connection in the blue terminals on the board. Connecting power cable from VFD to spindle Plug the electrical connector into the HSD spindle power plug. Depress the metal retainer clip until it snaps in place. Re-connect and turn on the control box. Verify that the fan powers up and starts turning when the control box is powered. NOTE: Ensure power is turned off before proceeding! Routing and connecting motor cables to motors The motor cables are pre-wired to the PRSstandard control box from ShopBot. Plug each motor cable to its color-coded motor. Route all the cables from the control box to the back of the machine. The Red X2 motor cable needs to be fed through the hole in the back endplate and gantry until it comes out the front endplate. The Blue (Y-axis) and White (Z-axis) cables should be routed over the gantry through the Y-axis E-chain and to the Y- & Z-axis motors. Copyright 2016 ShopBot Tools, Inc. page 10

11 The PRSstandard motors come with the mounting plate and pinions pre-installed. Slide the provided heat-shrink onto the cable before hooking it up. At this point the motors should be in their correct mounting location on the machine and should have the corresponding color motor cable routed to the correct motor. Caution: Make sure that X1 and X2 are connecting to the correct motor! Press connectors for the motors together. Making sure that the connectors are securely fastened, slide the heat-shrink over the connection. Use a heat gun or hair dryer to heat the heat shrink until it tightly envelopes the connection. This is important; this process helps to keep out dust and debris from these connections and helps to provide added safe guards against tampering and accidental disconnections. Copyright 2016 ShopBot Tools, Inc. page 11

12 Connecting Remote Stop Switch Cable The PRSstandard comes with a Remote Stop Switch. Hitting this Stop button will immediately stop the PRSstandard tool and keep it stopped until the switch is unlocked. his button also turns off the router/spindle. The blue wire terminal boxes at the bottom of the control board is where the remote stop switch, X&Y proximity switches, and the Z zero plate are connected. Refer to the wiring diagram above to wire in these peripherals. Note: The terminal blocks can be removed to make wire insertion easier. Note: Some of the terminal positions will have more than one wire. To install the remote stop, route the cable into the control box and connect the white wire to G (ground) and the black to 4/ST (input 4). Note: Any ground (labeled G ) will work for any ground wire. The ones labeled in the diagram were selected for their proximity to other companion wire attachment points or to prevent too many wires from going to one terminal block. Copyright 2016 ShopBot Tools, Inc. page 12

13 The blue wire terminal boxes at the bottom of the control board is where the remote stop switch, X&Y proximity switches, and the Z-zero plate are connected. Refer to the wiring diagram above to wire in these peripherals. Note: The terminal blocks can be removed to make wire insertion easier. Note: Some of the terminal positions will have more than one wire. To install the remote stop, route the cable into the control box and connect the white wire to G (ground) and the black to 4/ST (input 4). Note: Any ground (labeled G ) will work for any ground wire. The ones labeled in the diagram were selected for their proximity to other companion wire attachment points or to prevent too many wires from going to one terminal block. Connecting the Cables from the Proximity Switch and Z zero Plate Insert the black wire from the proximity switch cable for the X-axis into the blue terminal block labeled 2/PX (Input 2) on the control board. Insert the black wire from the proximity switch cable for the Y-axis and into 3/PY (Input 3) on the same terminal block. Join the blue wires from both of the switches together into a G (ground) terminal and join the brown wires from both of the switches and place them in the +24 (24V) terminal. Verify that when the PRSstandard control box is powered up, a red LED in the body of each proximity switch on the tool stays on until it is triggered by coming near a target. Connect the Z-zero plate. The black wire goes in the 1/ZZ (Input 1) terminal and the green wire goes into a G (ground) terminal. The red wire goes to +5 (5V) terminal. Note: the 5V terminal is only used by the Digitizing Probe. There is a USB cable connector wired into the control board. It is used for attaching the USB cable that will connect the control box to a computer. This connector is on a short cable that exits on the right side of the control board. Feed the longer 10ft cable supplied with the Shop- Bot through the Roxtec fixture and plug it into this connector. Do not plug the USB cable into the computer yet. Seal the Cable Entry After all the cables have been attached into the PRSstandard Control Box and onto the machine, install gaskets around them and close Roxtec fixture. Double check that the cables are properly installed and perform final adjustment and tightening. Ground the Dust Collection System If a dust collection system is installed, ground it to the System Ground. See the document titled Installing the PRS Dust Skirt for details on grounding the dust skirt hoses and dust collection device. Copyright 2016 ShopBot Tools, Inc. page 13

14 Connect USB Cable Ensure the ShopBot control software is installed on the computer. The USB cable provided is 10 feet long. If it is necessary to increase the length of the USB cable, use a USB 2.0 hub at the junction between the cable sections. Using a cable longer than 10 feet, without a hub as a booster, will increase electrical interference and may result in loss of signal. Remote Stop Switch The Remote Stop Switch comes with a long cable to allow the switch to be mounted in a convenient location. Keep the remote stop switch away from devices that have their own power source, such as the spindle or router, or a vacuum system. Mounting the Switch A good spot for mounting is on the front side of the X-Car, with the cable routed to the back of the tool through the center of the beam. Holes are pre-drilled in this location. Other good locations are on the side of the table, at the computer station, or on the wall near the ShopBot. There are a number of ways to attach the switch. These include mounting tape, Velcro, or screws. Four screws are provided in a plastic bag attached to the cable. On the back of the remote stop switch there are some slots in the plastic, which allows the screws to be fastened into the switch. Place the remote stop switch onto the X-Car and secure with four screws. Copyright 2016 ShopBot Tools, Inc. page 14

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